Mattresses including a zoned cushioning layer and related methods

ABSTRACT

Mattress assemblies are disclosed herein. The mattress assemblies can include a multilayered construction having a base layer, a coil layer, and a zoned cushioning layer. The zoned cushioning layer can include two or more cushioning members made of an elastomeric cushioning material. The cushioning members can be disposed in a hip region, a shoulder region, and/or a leg region of the mattress assembly. One or more support and/or comfort layers can also be included.

TECHNICAL FIELD

The present disclosure relates generally to mattress assemblies andrelated methods. More particular, the present disclosure relates tomattress assemblies including a zoned cushioning layer and relatedmethods.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments disclosed herein will become more fully apparent fromthe following description and appended claims, taken in conjunction withthe accompanying drawings. These drawings depict only typicalembodiments, which will be described with additional specificity anddetail through use of the accompanying drawings in which:

FIG. 1 is a perspective view of a mattress assembly according to oneembodiment of the present disclosure.

FIG. 2 is a cut away perspective view of the mattress assembly of FIG.1.

FIG. 3 is an exploded cross-sectional view of the mattress assembly ofFIG. 1.

FIG. 4 is a cross-sectional view of the mattress assembly of FIG. 1,depicted with a person laying on the mattress.

FIG. 5 is an exploded cross-sectional view of a mattress assemblyaccording to another embodiment of the present disclosure.

FIG. 6 is an exploded cross-sectional view of a mattress assemblyaccording to another embodiment of the present disclosure.

DETAILED DESCRIPTION

Mattress assemblies are disclosed herein. In some embodiments, themattress assemblies are multilayered assemblies that include a baselayer, a coil layer, and a zoned cushioning layer. One or moreadditional layers can also be included depending on the mattress designand/or configuration. For example, in certain embodiments, the mattressassemblies include a base layer, a coil layer, a zoned cushioning layer,and one or more support and/or comfort layers. In a particularembodiment, the one or more support and/or comfort layers comprise oneor more foam layers. These and other embodiments are further detailedbelow.

As set forth herein, embodiments may be understood by reference to thedrawings, wherein like parts are designated by like numerals throughout.It will be readily understood by one of ordinary skill in the art havingthe benefit of this disclosure that the components of the embodiments,as generally described and illustrated in the figures herein, could bearranged and designed in a wide variety of different configurations.Thus, the following more detailed description of various embodiments, asrepresented in the figures, is not intended to limit the scope of thedisclosure but is merely representative of various embodiments. Whilethe various aspects of the embodiments are presented in drawings, thedrawings are not necessarily drawn to scale unless specificallyindicated.

It will be appreciated that various features are sometimes groupedtogether in a single embodiment, figure, or description thereof for thepurpose of streamlining the disclosure. Many of these features may beused alone and/or in combination with one another.

The phrases “coupled to” and “in communication with” refer to any formof interaction between two or more entities, including mechanical,electrical, magnetic, electromagnetic, fluid, and thermal interaction.Two components may be coupled to or in communication with each othereven though they are not in direct contact with each other. For example,two components may be coupled to or in communication with each otherthrough an intermediate component.

The phrase “elastomeric polymer” refers to a polymer capable ofrecovering or substantially recovering its original size and shape afterdeformation. In other words, an elastomeric polymer is a polymer havingelastic or viscoelastic properties. Elastomeric polymers may also bereferred to as “elastomers.” Elastomeric polymers include, withoutlimitation, homopolymers (polymers having a single chemical unitrepeated) and copolymers (polymers having two or more chemical units).

The phrase “elastomeric block copolymer” refers to an elastomericpolymer having groups or blocks of homopolymers linked together, such asA-B diblock copolymers and A-B-A triblock copolymers. A-B diblockcopolymers have two distinct blocks of homopolymers. A-B-A triblockcopolymers have two blocks of a single homopolymer (A) each linked to asingle block of a different homopolymer (B).

The phrase “elastomeric material” refers to elastomeric polymers andmixtures of elastomeric polymers with plasticizers and/or othermaterials. Elastomeric materials are elastic (i.e., capable ofrecovering size and shape after deformation). Elastomeric materialsinclude, without limitation, materials referred to in the art as“elastomer gels,” “gelatinous elastomers,” or simply “gels.”

Any relational and/or directional term, such as “first,” “second,”“top,” “bottom” etc., is used for clarity and convenience inunderstanding the disclosure and accompanying drawings, and does notconnote or depend on any specific preference or order, except where thecontext clearly indicates otherwise. For example, these terms may referto an orientation of elements of a mattress when oriented for sleepingin a conventional manner. Furthermore, these terms may refer to anorientation of elements of a mattress assembly as illustrated in thedrawings.

FIGS. 1-3 depict various views of a mattress assembly 100 according toan embodiment of the present disclosure. More particularly, FIG. 1 is aperspective view of the mattress assembly 100; FIG. 2 is a cut-awayperspective view of the mattress assembly 100; and FIG. 3 is an explodedcross-sectional view of the mattress assembly 100.

As shown in the illustrated embodiment, the mattress assembly 100includes a multilayered construction. For instance, the mattressassembly 100 includes a base layer 110, a coil layer 120, and a zonedcushioning layer 130. One or more additional layers can also be includeddepending on the mattress design and/or configuration. For example, incertain embodiments the mattress assemblies 100 include a base layer110, a coil layer 120, a zoned cushioning layer 130, and one or moresupport and/or comfort layers 140, 150, 160. In particular embodiments,the one or more support and/or comfort layers 140, 150, 160 comprise oneor more foam layers.

With continued reference to FIGS. 1-3, the base layer 110 is generallydisposed on the bottom of the mattress assembly 100 and provides a baseor foundation upon which the remaining layers are disposed. The baselayer 110 can comprise various materials, including, but not limited to,a foam material such as a polyurethane foam or latex foam. Foams andother forms of polyethylene, polypropylene, fiber, and/or latex can alsobe used. In some embodiments, the base layer 110 comprises a foammaterial (e.g., polyurethane foam) having a density of between about 1lbs/ft³ and about 5 lbs/ft³, between about 1 lbs/ft³ and about 4lbs/ft³, between about 1 lbs/ft³ and about 3 lbs/ft³, or between about 1lbs/ft³ and about 2 lbs/ft³. The base layer 110 can also comprise anindentation load deflection (ILD) of between about 20 lbs and about 100lbs, between about 30 lbs and about 70 lbs, or between about 40 lbs andabout 60 lbs. As used herein, the indentation load deflection (ILD) isthe amount of force (in pounds) required to indent the foam or layer atotal of 25 percent of its original thickness. The thickness T₁ of thebase layer 110 can also vary. In some embodiments, the base layer 110comprises a thickness of between about 1 inch and about 18 inches,between about 1 inch and about 12 inches, between about 1 inch and about5 inches, or between about 1 inch and about 3 inches. For instance,greater thicknesses can be used in instances in which the base layer 110serves as a core layer and the mattress assembly 100 is devoid of a coillayer 120. In such embodiments, the zoned cushioning layer 130 can bedisposed on the base layer 110.

The coil layer 120 is disposed on the base layer 110. As shown in FIGS.2 and 3, the coil layer 120 can include a plurality of coils 122, eachof which may be encased in at least one respective casing or cover 124.For example, each casing 124 may form a pocket for a respective coil122. In such embodiments, the plurality of coils 122 may be referred toas a plurality of pocketed cods 122. In some embodiments, each coil 122may include a relatively thin-gauge, barrel-shaped (e.g.,helical-shaped), knotless coil. The coils 122 may comprise a metalmaterial, such as steel. In other embodiments, the coils 122 are formedfrom a polymeric material such as a foam or gel. Further, in certainembodiments each coil 122 may be encased in multiple casings 124. Forinstance, each coil 122 may be double bagged or triple bagged. In someembodiments, the casings 124 may include a polypropylene material. Othermaterials can also be used. For instance, in some embodiments, theplurality of cons 122 are encased in a foam material, which may or maynot include an additional casing 124.

As further illustrated, in some embodiments each casing 124 and eachcoil 122 of the plurality of cons 122 may be individual and discrete. Incertain embodiments, the casings 124 of the plurality of coils 122 maybe coupled or otherwise joined to one another. Further, each coil 122 ofthe plurality of cons 122 may extend longitudinally in a direction atleast substantially orthogonal (i.e., normal) to an upper surface of thebase layer 110. The plurality of cods 122 may be oriented next to eachother in an array (e.g., rows and columns or a grid pattern) to form thecoil layer 120. In other embodiments, the coil layer 120 does notcomprise coils 122 that are individual and discrete units. Rather, thecoil layer 120 can comprise a continuous wire unit, or coil orspring-like structures that are not barrel shaped. Any such innerspringunits can be used in the coil layer 120. Further in particularembodiments, the coils 122 of the coil layer 120 are substituted withgel structures or air pockets that can function as the coil layer 120.

The number of coils 122 in the coil layer 120 can vary depending on thesize and/or shape of the mattress assembly 100. The height or thicknessT₂ of the coil layer 120 can also vary. In some embodiments, the coillayer 120 comprises a thickness of between about 4 inches and about 10inches, or between about 5 inches and about 8 inches. Other thicknessesare also contemplated. For instance, coil layers 122 comprising othertypes of innerspring units, foam or gel coils, or air pockets can have athickness T₂ that is less than about 5 inches, about 4 inches, about 3inches, or about 2 inches.

The coil layer 120 can further comprise a rail or sidewall 126 extendingaround the plurality of coils 122 or innerspring units. For example, asshown in the illustrated embodiment, the sidewall 126 extends around aperimeter or periphery of the coil layer 120. The sidewall 126 can beconfigured to retain the coils 122 or innerspring units within a centralregion of the coil layer 120. In some embodiments, the sidewall 126comprises a foam material, such as a polyurethane foam or a latex foam.The sidewall 126 can also comprise wood, metal, or other reinforcingmembers if desired. Other types of materials can also be used,including, but not limited to, foams and other forms of polyethylene,polypropylene, fiber, and/or latex. The thickness of the sidewall 126can be substantially the same thickness as the coils 122 within the coillayer 120. The width W₂ of the sidewall 126 can be between about 1 inchand about 10 inches.

As previously discussed, the mattress assembly 100 further includes azoned cushioning layer 130. This zoned cushioning layer 130 includes aplurality of individual or discrete regions or zones of cushioningmembers 132 so as to provide a zoned arrangement. As shown in theillustrated embodiment, the regions of cushioning members 132 extendlaterally across the mattress assembly 100. The regions of cushioningmembers 132 are also spaced along a longitudinal length of the mattressassembly 100. Regions of a support material 134, such as a polyurethanefoam or latex foam, are disposed between and around the regions of thecushioning members 132. Foams and other forms of polyethylene,polypropylene, fiber, and/or latex can also be used as the supportmaterial 134. Flat foams or convoluted foams can be used. In someembodiments, the zoned cushioning layer 130 includes two or more regionsof cushioning member 132. In further embodiments, the zoned cushioninglayer 130 includes three or more regions of cushioning member 132. Inyet further embodiments, the zoned cushioning layer 130 includes four orfive or more regions of cushioning member 132.

In some embodiments, the regions of cushioning member 132 can bedisposed at areas of which increased pressure or weight is expected tobe applied from a subject during use of the mattress assembly 100. Forinstance, a first region of cushioning member 132 a can be disposed in ahip region and a second region of cushioning member 132 b can bedisposed at a shoulder region. In some embodiments, a third region ofcushioning member 132 c can be disposed at a leg region. This isexemplified in FIG. 4, which depicts a subject 10 laying on the mattressassembly 100. As shown in FIG. 4, the subject's hips 12 are generallyaligned within the first region of the cushioning member 132 a, thesubject's shoulders 14 are generally aligned within the second region ofthe cushioning member 132 b, and a portion of the subject's lower legs16 are generally aligned within the third region of the cushioningmember 132 c. Providing the cushioning members 132 a, 132 b, 132 c insuch areas can increase the comfort of the mattress assembly 100 as thehips, shoulders, and lower legs are known to exhibit increased pressureon the mattress assembly 100. In some embodiments, the regions ofcushioning member 132 are symmetrically disposed along a longitudinallength of the mattress assembly 100. In such embodiments, the mattressassembly 100 can be rotated 180 degrees such that the subject'sshoulders 14 generally align with the third region of the cushioningmember 132 c, and the subject's lower legs 16 generally align with thesecond region of the cushioning member 132 b.

The width W₃ of the cushioning members 132 can vary. For instance, thewidth W₃ of the cushioning members 132 can be between about 6 inches andabout 20 inches, between about 8 inches and about 20 inches, or betweenabout 12 inches and about 20 inches. In some embodiments, each of thecushioning members 132 comprises the same width W₃. In otherembodiments, the cushioning members 132 can comprise different widthsW₃. For instance, in some embodiments, the width W₃ of the cushioningmember 132 a in the hip region is greater than the width W₃ of thecushioning members 132 b, 132 c in the shoulder region and/or legregion. In some of such embodiments, the width W₃ of the cushioningmember 132 a in the hip region is between about 12 inches and about 20inches, and the width W₃ of the cushioning members 132 b, 132 c in theshoulder region and/or leg region is between 8 inches and about 15inches. Other widths W₃ and/or sizes are also contemplated.

Various materials can be used in the cushioning members 132. In someembodiments, each region of cushioning member 132 comprises anelastomeric cushioning material. Each region of elastomeric cushioningmember 132 may also include buckling walls. The buckling walls of theelastomeric cushioning member 132 may be interconnected to one anotherand may define hollow columns or voids in an expanded form. The term“expanded form” can refer to a state in which the elastomeric cushioningmember 132 has its original size and shape and wherein the bucklingwalls are separated and define hollow columns.

The buckling walls may extend in two directions, intersecting at rightangles, and defining square or rectangular voids. The buckling walls maydefine a grid structure. However, in some embodiments, the bucklingwalls may intersect at other angles and define voids of other shapes,such as triangles, parallelograms, hexagons, etc. The elastomericcushioning member 132 may comprise additional structures andconfigurations such as those structures and configurations described in,for example, U.S. Pat. No. 5,749,111, titled “Gelatinous Cushions withBuckling Columns,” issued May 12, 1998; U.S. Pat. No. 6,026,527, titled“Gelatinous Cushions with Buckling Columns,” issued Feb. 22, 2000; andU.S. Pat. No. 7,076,822, titled “Stacked Cushions,” issued Jul. 18,2006, the entire disclosure of each of which is incorporated herein byreference.

The buckling walls may be formed of an elastomeric material. Exemplaryelastomeric materials are described in, for example, U.S. Pat. No.5,994,450, titled “Gelatinous Elastomer and Methods of Making and Usingthe Same and Articles Made Therefrom,” issued Nov. 30, 1999, and U.S.Pat. No. 7,964,664, titled “Gel with Wide Distribution of MW inMid-Block” issued Jun. 21, 2011, the disclosures of each of which areincorporated herein by reference in theft entirety. In some embodiments,the elastomeric material may include an elastomeric polymer and aplasticizer. The elastomeric material may be a gelatinous elastomer(which can also be referred to as a gel, an elastomer gel, or anelastomeric gel), a thermoplastic elastomer, a natural rubber, asynthetic elastomer, a blend of natural and synthetic elastomers, etc.

In some embodiments, the elastomeric polymer may be a block copolymer.For instance, the elastomeric polymer may be an A-B diblock copolymer.In some embodiments, the elastomeric polymer may be an A-BA triblockcopolymer such as styrene ethylene propylene styrene (SEPS), styreneethylene butylene styrene (SEPS), and styrene ethylene propylene styrene(SEEPS). The elastomeric material may also include elastomeric polymersother than styrene-based copolymers, such as non-styrenic elastomericpolymers that are thermoplastic in nature or that can be solvated byplasticizers or that are multi-component thermoset elastomers. Theelastomeric material may optionally include one or more plasticizers,such as hydrocarbon fluids.

The elastomeric material may include any type of gelatinous elastomer.The elastomeric material may include a material that may return to itsoriginal shape after deformation, and that may be elastically stretched.The elastomeric material may be rubbery in feel, but may deform to theshape of an object applying a deforming pressure better thanconventional rubber materials, and may have a durometer hardness lowerthan conventional rubber materials. For example, the elastomericmaterial may have a hardness on the Shore A scale of less than about 50,from about 0.1 to about 50, or less than about 5.

With continued reference to FIGS. 2 and 3, the areas or regions of thezoned cushioning layer 130 between and around the cushioning members 132can comprise a support material 134, such as a polyurethane foam orlatex foam. Foams and other forms of polyethylene, polypropylene, fiber,and/or latex can also be used as the support material 134. Flat foams orconvoluted foams can be used. In further embodiments, the areas orregions 134 of the zoned cushioning layer 130 between and around thecushioning members 132 comprise an elastomeric cushioning material orgel having one or more different properties than the material in thecushioning members 132. In such embodiments, the materials identifiedabove for the regions of zoned cushioning member 132 can also be used asthe support material 134, but with one or more different properties suchas a different firmness, hardness, structure, chemical composition, etc.In certain embodiments, the width W₄ of support material 134 betweenadjacent regions of zoned cushioning members 132 is at least about 4inches, at least about 6 inches, or more. As illustrated, the supportmaterial 134 can extend around a perimeter or periphery of the zonedcushioning layer 130. The support material 134 can also extend betweenthe various regions of cushioning member 132. The properties of thesupport material 134 can also differ from the properties of thecushioning member 132. For instance, in some embodiments the supportmaterial 134 can have a stiffness or rigidity that is different from orgreater than the cushioning member 132. In certain embodiments, thesupport material 134 can be configured to aid in maintaining thestructural conformation of the zoned cushioning layer 130. For instance,the support material 134 along the perimeter or periphery of the zonedcushioning layer 130 can provide increased support for a subject to siton a side or edge of the mattress assembly 100. In other embodiments,the stiffness or rigidity of the support material 134 is substantiallythe same as that of the cushioning members 132.

The thickness T₃ of the zoned cushioning layer 130 can vary as desired.In some embodiments, the zoned cushioning layer 130 may have a thicknessT₃ of within a range of about 0.75 inches to about 5 inches, about 1inch to about 4 inches, or between about 1.5 inches to about 3 inches.Other thicknesses are also contemplated. It will further be appreciatedthat in some embodiments the mattress assembly 100 can include two ormore zoned cushioning layers 130. These two more zoned cushioning layers130 can be stacked vertically, either directly adjacent one another orwith one or more additional layers in between.

As previously discussed, the mattress assembly 100 can further compriseone or more optional and/or additional layers depending on the mattressdesign and/or configuration. For example, one or more support and/orcomfort layers 140, 150, 160 can be included on either or both sides ofthe zoned cushioning layer 130. In some embodiments, such as theillustrated embodiment, one or more support and/or comfort layers 140,150, 160 are optionally disposed between the coil layer 120 and thezoned cushioning layer 130. With reference to FIGS. 2 and 3, forexample, at least one or a first support layer 140 is disposed betweenthe coil layer 120 and the zoned cushioning layer 130. This firstsupport layer 140 can provide additional support and structuralconformation to the mattress assembly 100. For instance, the firstsupport layer 140 can comprise a stiffness or rigidity that is greaterthan that of the zoned cushioning layer 130. The first support layer 140can also provide a different feel to the mattress assembly 100. Incertain embodiments, the first support layer 140 comprises a foammaterial, such as a polyurethane foam or a latex foam. Foams and otherforms of polyethylene, polypropylene, fiber, and/or latex can also beused. Flat foams or convoluted foams can be used. In particularembodiments, the first support layer 140 comprises a foam material(e.g., polyurethane foam) having a density of between about 1 lbs/ft³and about 5 lbs/ft³, between about 1 lbs/ft³ and about 4 lbs/ft³,between about 1 lbs/ft³ and about 3 lbs/ft³, or between about 1 lbs/ft³and about 2 lbs/ft³. The first support layer 140 can also comprise anindentation load deflection (ILD) of between about 20 lbs and about 100lbs, between about 10 lbs and about 40 lbs, or between about 10 lbs andabout 30 lbs. The thickness T₄ of the first support layer 140 can alsovary. In some embodiments, the thickness T₄ of the first support layer140 is between about 0.5 inches and about 2 inches, or between about 0.5inches and about 1.5 inches. Other thicknesses T₄ can also be used, suchas between about 1 inch and about 18 inches, between about 1 inch andabout 12 inches, between about 1 inch and about 5 inches, or betweenabout 1 inch and about 3 inches.

One or more additional support and/or comfort layers can also bedisposed between the coil layer 120 and the zoned cushioning layer 130if desired. The one or more additional support and/or comfort layers cancomprise a different material than the first support layer 140, such asa different foam material or foam having a different density and/orindentation load deflection (ILD) to impart additional properties to themattress assembly 100.

One or more additional layers 150, 160 can also be disposed above thezoned cushioning layer 130 if desired. For instance, in the illustratedembodiment, the mattress assembly 100 comprises two additional layers150, 160 disposed above the zoned cushioning layer. In some embodiments,the mattress assembly 100 comprises at least one comfort layer 150disposed above the zoned cushioning layer 130. In particularembodiments, the at least one comfort layer 150 comprises a memorymaterial, such as a polyurethane memory foam material. The memory foammaterial can include polyurethane material that is viscoelastic and canbe configured to contour to the body of a subject during use. Flat foamsor convoluted foams can be used. The thickness T₅ of the comfort layer150 can also vary. In some embodiments, the comfort layer 150 comprisesa thickness T₅ of between about 0.5 inches and about 3 inches, orbetween about 0.75 inches and about 2 inches.

One or more additional support and/or comfort layers can also bedisposed above the zoned cushioning layer 130. For instance, in someembodiments, one or more support layers 160 are also disposed betweenthe zoned cushioning layer 130 and the comfort layer 150. In suchembodiments, the support layer 160 can comprise a different materialthan the comfort layer 150, such as a different foam material or foamhaving a different density to impart additional properties to themattress assembly 100. In certain embodiments, the support layer 160comprises a material having a higher stiffness or rigidity than thecomfort layer 150 and can provide additional support and structuralconformation to the mattress assembly 100, similar to the first supportlayer 140. In some embodiments, the second support layer 160 comprises afoam material, such as a polyurethane foam or a latex foam. Foams andother forms of polyethylene, polypropylene, fiber, and/or latex can alsobe used. Flat foams or convoluted foams can be used. In particularembodiments, the support layer 160 comprises a foam material (e.g.,polyurethane foam) having a density of between about 1 lbs/ft³ and about5 lbs/ft³, between about 1 lbs/ft³ and about 4 lbs/ft³, between about 1lbs/ft³ and about 3 lbs/ft³, or between about 1 lbs/ft³ and about 2lbs/ft³. The support layer 160 can also comprise an indentation loaddeflection (ILD) of between about 20 lbs and about 100 lbs, betweenabout 10 lbs and about 70 lbs, such as between about 10 lbs and about 25lbs, or between about 40 lbs and about 60 lbs depending on the desiredfirmness. The thickness T₆ of the support layer 160 can also vary. Insome embodiments, the support layer 160 comprises a thickness of betweenabout 0.5 inches and about 3 inches, or between about 0.75 inch andabout 2 inches. Other thicknesses T₆ can also be used, such as betweenabout 1 inch and about 18 inches, between about 1 inch and about 12inches, between about 1 inch and about 5 inches, or between about 1 inchand about 3 inches.

In certain embodiments, one or more of the additional support and/orcomfort layers 140, 150, 160 comprises a layer of elastomeric cushioningmaterial or gel. In such embodiments, the materials and structures(e.g., buckling walls defining hollow columns) identified above for theregions of zoned cushioning member 132 can also be used in the one ormore additional support and/or comfort layers 140, 150, 160. The one ormore additional support layers 140, 150, 160 comprising a layer ofelastomeric cushioning material or gel can be stacked vertically on oneor both sides of the zoned cushioning layer 130, either directlyadjacent the zoned cushioning layer 130 or with one or more additionallayers in between.

With reference to FIG. 1, the mattress assembly 100 can also comprise acover 105 disposed at least partially around or encapsulating theentirety of multilayered construction. Various types of covers 105 canbe used, including quilted or padded covers 105 and the like. The cover105 can also comprise various materials or fabrics, including, but notlimited to, cotton materials, polyester materials, polymeric materials,water resistant materials, synthetic materials, and combinationsthereof. The cover 105 can be flexible and stretchable (or elastic) suchthat it can stretch and return to its original size and/or shape.

The mattress assembly 100 can further include adhesives, stitching, orother fasteners for coupling the one or more layers 110, 120, 130, 140,150, 160 together. In some embodiments, stabilization materials are alsodisposed between the layers. Stabilization materials can includenon-slip materials or adhesive materials such that lateral orlongitudinal movement between the layers is minimized. In certainembodiments, each of the cushioning members 132 includes a stabilizationmaterial coupled on one or both of the top and bottom surfaces of thecushioning member 132. The stabilization material can include arelatively thin material (e.g., a scrim) and may be used to providestructural conformation to the cushioning member 132 and/or aid inadhering the cushioning member 132 to surrounding materials or layers.In certain embodiments, the stabilization material can include a scrimor fabric (woven or non-woven) and portions of the cushioning member 132can seep through (e.g., be melt-fused into, bleed through, push through,leak through, pass through, etc.) the stabilization material to therebycouple the cushioning member 132 to the stabilization material. Forinstance, a cushioning member 132 comprising a gelatinous elastomer canbe heat fused through the stabilization material.

FIG. 5 depicts a mattress assembly 200 according to another embodiment.As shown in FIG. 5, the mattress assembly 200 includes a base layer 210,a coil layer 220, and a zoned cushioning layer 230. The mattressassembly 200 further includes one or more additional support and/orcomfort layers 240, 250, 260.

In particular, the mattress assembly 200 of FIG. 5 includes two supportand/or comfort layers 240, 260 disposed between the coil layer 220 andzoned cushioning layer 230. An additional support and/or comfort layer250 is also disposed above the zoned cushioning layer 230. Thus, asillustrated in FIG. 5, the arrangement and number of support and/orcomfort layers 240, 250, 260 can vary depending on the mattressconfiguration.

FIG. 6 depicts a mattress assembly 300 according to yet anotherembodiment. As shown in FIG. 6, the mattress assembly 300 includes abase layer 310, a coil layer 320, and a zoned cushioning layer 330. Themattress assembly 300 further includes one or more additional supportand/or comfort layers 340, 350.

In particular, the mattress assembly 300 of FIG. 6 includes one supportand/or comfort layer 340 disposed between the coil layer 320 and zonedcushioning layer 330. An additional support and/or comfort layer 350 isalso disposed above the zoned cushioning layer 330. Thus, as illustratedin FIG. 6, the arrangement and number of support and/or comfort layers340, 350 can vary depending on the mattress configuration.

Without limitation, it will be appreciated that the zoned cushioninglayer of the present disclosure can be incorporated into various typesof mattress assemblies and configurations. For instance, the zonedcushioning layer can be incorporated into traditional mattressassemblies and configurations. The zoned cushioning layer can also beincorporated into mattress assemblies that can be folded or rolled intopackaging materials. Incorporation of the zoned cushioning layer intoother types of mattress assemblies is also within the scope of thisdisclosure.

It will further be appreciated that any methods disclosed hereincomprise one or more steps or actions for performing the describedmethod. The method steps and/or actions may be interchanged with oneanother. In other words, unless a specific order of steps or actions isrequired for proper operation of the embodiment, the order and/or use ofspecific steps and/or actions may be modified. Methods contemplated bythe present disclosure include methods of manufacturing a mattressassembly having a base layer, a coil layer, and a zoned cushioninglayer. Other methods can also be employed.

References to approximations are made throughout this specification,such as by use of the term “about.” For each such reference, it is to beunderstood that, in some embodiments, the value, feature, orcharacteristic may be specified without approximation. For example,where qualifiers such as “about” and “substantially” are used, theseterms include within their scope the qualified words in the absence oftheir qualifiers. All ranges also include both endpoints.

Similarly, in the above description of embodiments, various features aresometimes grouped together in a single embodiment, figure, ordescription thereof for the purpose of streamlining the disclosure. Thismethod of disclosure, however, is not to be interpreted as reflecting anintention that any claim require more features than those expresslyrecited in that claim. Rather, as the following claims reflect,inventive aspects lie in a combination of fewer than all features of anysingle foregoing disclosed embodiment.

The claims following this written disclosure are hereby expresslyincorporated into the present written disclosure, with each claimstanding on its own as a separate embodiment. This disclosure includesall permutations of the independent claims with their dependent claims.Moreover, additional embodiments capable of derivation from theindependent and dependent claims that follow are also expresslyincorporated into the present written description.

Without further elaboration, it is believed that one skilled in the artcan use the preceding description to utilize the invention to itsfullest extent. The claims and embodiments disclosed herein are to beconstrued as merely illustrative and exemplary, and not a limitation ofthe scope of the present disclosure in any way. It will be apparent tothose having ordinary skill in the art, with the aid of the presentdisclosure, that changes may be made to the details of theabove-described embodiments without departing from the underlyingprinciples of the disclosure herein. In other words, variousmodifications and improvements of the embodiments specifically disclosedin the description above are within the scope of the appended claims.Moreover, the order of the steps or actions of the methods disclosedherein may be changed by those skilled in the art without departing fromthe scope of the present disclosure. In other words, unless a specificorder of steps or actions is required for proper operation of theembodiment, the order or use of specific steps or actions may bemodified. The scope of the invention is therefore defined by thefollowing claims and their equivalents.

1. A mattress assembly, comprising: a base layer; a coil layer; and azoned cushioning layer, wherein the zoned cushioning layer comprises atleast two cushioning members spaced apart along a longitudinal length ofthe zoned cushioning layer, each of the cushioning members extendinglaterally across the zoned cushioning layer.
 2. The mattress assembly ofclaim 1, wherein the base layer comprises a polyurethane foam or a latexfoam.
 3. The mattress assembly of claim 1, wherein the coil layercomprises a plurality of encased metal coils.
 4. The mattress assemblyof claim 1, wherein the zoned cushioning layer comprises threecushioning members spaced apart along the longitudinal length of thezoned cushioning layer.
 5. The mattress assembly of claim 1, whereineach of the cushioning members comprises an elastomeric cushioningmaterial.
 6. The mattress assembly of claim 5, wherein the elastomericcushioning material comprises a styrene-based copolymer.
 7. The mattressassembly of claim 1, wherein each cushioning member comprises aplurality of buckling walls that define hollow columns.
 8. The mattressassembly of claim 1, further comprising a support layer disposed betweenthe coil layer and the zoned cushioning layer.
 9. The mattress assemblyof claim 1, further comprising a comfort layer disposed above the zonedcushioning layer, the comfort layer comprising a memory material. 10.The mattress assembly of claim 9, further comprising a support layerdisposed between the zoned cushioning layer and the comfort layer.
 11. Amattress assembly, comprising: a base layer; a coil layer; and a zonedcushioning layer, wherein the zoned cushioning layer comprises at leastthree cushioning members spaced apart along a longitudinal length of thezoned cushioning layer, each of the cushioning members extendinglaterally across the zoned cushioning layer; wherein a first cushioningmember is disposed in a hip region, a second cushioning member isdisposed in a shoulder region, and a third cushioning member is disposedin a leg region; and wherein each cushioning member comprises anelastomeric material that comprises a plurality of buckling walls thatdefine hollow columns.
 12. The mattress assembly of claim 11, whereinthe base layer comprises a polyurethane foam or a latex foam.
 13. Themattress assembly of claim 11, wherein the coil layer comprises aplurality of encased metal coils.
 14. The mattress assembly of claim 11,wherein the elastomeric cushioning material comprises a styrene-basedcopolymer.
 15. The mattress assembly of claim 11, further comprising asupport layer disposed between the coil layer and the zoned cushioninglayer.
 16. The mattress assembly of claim 11, further comprising acomfort layer disposed above the zoned cushioning layer, the comfortlayer comprising a memory material.
 17. The mattress assembly of claim16, further comprising a support layer disposed between the zonedcushioning layer and the comfort layer.
 18. A mattress assembly,comprising: a base layer; a coil layer; a first support layer; a zonedcushioning layer, wherein the zoned cushioning layer comprises at leastthree cushioning members spaced apart along a longitudinal length of thezoned cushioning layer, each of the cushioning members extendinglaterally across the zoned cushioning layer, wherein a first cushioningmember is disposed in a hip region, a second cushioning member isdisposed in a shoulder region, and a third cushioning member is disposedin a leg region, and wherein each cushioning member comprises anelastomeric material that comprises a plurality of buckling walls thatdefine hollow columns; and a comfort layer.
 19. The mattress assembly ofclaim 18, wherein the comfort layer comprises a memory material.
 20. Themattress assembly of claim 18, wherein the elastomeric cushioningmaterial comprises a styrene-based copolymer.